Accelerating Low-Cost Perovskite Module Manufacturing with High-Throughput Open-Air Techniques

Low-cost perovskite PV module manufacturing is achieved with scalable open-air Rapid Spray Plasma Processing (RSPP). RSPP employs uniform ultrasonic spray deposition accompanied by multimodal plasma curing for high-throughput perovskite fabrication in open-air. The multiple plasma curing sources of heat, reactive gaseous species, and UV light enable perovskite curing times of < 1 second and linear throughputs of up to 20 cm/s. Machine learning optimization is employed for the establishment of ideal process parameters and solution chemistries, lending to recent champion open-air perovskite device performances of 19.54% and module performances of 17.43% across 10 cm deposition lengths. Accompanying technoeconomic analysis translating lab-scale open-air perovskite module fabrication to a 100 MW pilot-scale system anticipates >60% cost reduction with open-air spray-based perovskite module manufacturing compared to conventional solution deposition and vacuum-based processes. This enables target Levelized Cost of Energy (LCOE) of <$0.03/kWh for low-cost RSPP perovskite modules at only 10 – 15-year module lifetimes, providing a promising candidate for next-generation PV.